Apparatus for brewing and method for making the same

ABSTRACT

Apparatus for brewing a brew substance with a liquid comprises: a container for storing the liquid, the container including at least one aperture for dispensing liquid therefrom; a sealed packet of filter paper containing the brew substance; and a layer of heat sensitive film encapsulating the sealed packet, the encapsulated packet disposed within the container at a position covering the at least one aperture, the container configured to sit on top of a drinking container to permit liquid to drain into the drinking container from the at least one aperture thereof. In addition, a method of making a brewing apparatus comprises the steps of: configuring a container to store liquid for brewing and to dispense the liquid through at least one aperture therein; encapsulating a sealed packet of filter paper containing a brew substance with a layer of heat sensitive film; disposing the encapsulated packet within the container at a position covering the at least one aperture; and configuring the container to sit on top of a drinking container to permit liquid to drain into the drinking container from the at least one aperture thereof.

This utility application is a continuation of and claims the benefit ofthe filing date of U.S. patent application Ser. No. 10/937,720 (filed onSep. 9, 2004), and also claims the benefit of the filing dates of U.S.Provisional Application Nos. 60/501,292 (filed Sep. 9, 2003), 60/528,547(filed Dec. 10, 2003), and 60/546,518 (filed Feb. 20, 2004), and theentire contents of all such applications are incorporated by referenceherein.

BACKGROUND OF THE INVENTION

The present invention is directed to brewing apparatus in general, andmore particularly, to apparatus suitable for use in a microwave oven forbrewing a brew substance into a liquid and a method of making suchapparatus.

Disposable microwavable coffee brewers suitable for a one-cup servinghave been described in the literature. In these brewers, water is addedto a water reservoir and the brewer with water is placed over theconsumer's cup or mug which is of any known type for receiving a hotbeverage. The brewer and cup are then placed in a microwave oven whereinmicrowave brewing at appropriate settings may take approximately 5 orless minutes. During the brewing operation, the water is heated in thereservoir and at the desired temperature, the water is mixed with acharge of coffee in a brew chamber below the reservoir. The brewedcoffee is eventually dispensed by gravity from the brew chamber into thedrinking container.

One such microwavable coffee brewer is disclosed in U.S. Pat. No.5,243,164, entitled “Beverage Maker” which was granted Sep. 7, 1993 toErickson et al. In the Erickson brewer, a liquid reservoir includes atleast one aperture at the bottom thereof for dispensing a brewed liquidinto a drinking container. Filter paper is disposed over the at leastone aperture at the bottom of the reservoir and a charge of coffeegrinds is disposed over the filter paper. A partition of heat responsivefilm is disposed over the charge of coffee grinds and attached to theinside circumference of the reservoir to prevent liquid within thereservoir from mixing with the coffee grinds until the liquid reachesthe proper temperature.

To brew coffee with the Erickson brewer, the reservoir is filled with aproper amount of water and disposed over a drinking cup or mug. Then,the reservoir and cup are placed into a microwave oven which is set tostart with the desired settings for heating. As the temperature of thewater reaches the melting temperature of the partition material, thepartition ruptures and exposes the water to the coffee grinds forbrewing. The brewed coffee releases by gravity to the cup through thefilter paper and at least one aperture of the reservoir.

While the Erickson brewer mentions the use of a nitrogen purged (i.e.filled) retail bag for keeping multiple assembles preserved, theindividual brewers, particularly their respective coffee charges, arenot individually sealed. Accordingly, the freshness of the coffee willbegin to degrade as soon as the multiple unit package is ruptured. Also,the Erickson brewer permits flow-through brewing immediately uponrupture of the partition, thereby prohibiting a gradual wetting of thegrounds prior to the introduction of the brewing liquid into the servingcup. This absence of gradual wetting may allow air pockets to remain inboth the grounds and the paper which, in turn, has the potential ofcompromising the extraction process in and around these air pockets.

Still further, the Erickson brewer provides no provisions for a filterpaper layer above the grounds. One drawback of this design is thatbuoyant grounds may rise into the liquid reservoir, in turn, mitigatingthe hydraulic drag of the grounds remaining in the brew chamber andpermitting a higher flow rate which eventually results in lessextraction. Another drawback of this design is that the grounds shouldbe retained and held where the fluid head pressure is the greatest (i.e.as low as possible relative to the centroid of the reservoir). Buoyantgrounds floating on or near the surface of the liquid do not have thebenefit of head pressure to aid in the extraction process. Moreover, theappearance of grounds in the liquid reservoir is aestheticallyundesirable, and, if the reservoir is to be reused, a cleaning burden.

Accordingly, the present invention overcomes the foregoing describeddrawbacks of the current brewers by providing improved brewing apparatusand a method making the same.

SUMMARY OF THE INVENTION

In accordance with one aspect of the present invention, apparatus forbrewing a brew substance with a liquid comprises: a container forstoring the liquid, the container including at least one aperture fordispensing liquid therefrom; a sealed packet of filter paper containingthe brew substance; and a layer of heat sensitive film encapsulating thesealed packet, the encapsulated packet disposed within the container ata position covering the at least one aperture, the container configuredto sit on top of a drinking container to permit liquid to drain into thedrinking container from the at least one aperture thereof.

In accordance with another aspect of the present invention, a method ofmaking a brewing apparatus comprises the steps of: configuring acontainer to store liquid for brewing and to dispense the liquid throughat least one aperture therein; encapsulating a sealed packet of filterpaper containing a brew substance with a layer of heat sensitive film;disposing the encapsulated packet within the container at a positioncovering the at least one aperture; and configuring the container to siton top of a drinking container to permit liquid to drain into thedrinking container from the at least one aperture thereof.

In accordance with yet another aspect of the present invention,apparatus for brewing a brew substance with a liquid comprises: acontainer for storing the liquid, the container including at least oneaperture for dispensing liquid therefrom; an encapsulated packet of heatsensitive film containing the brew substance; and a layer of filterpaper covering the encapsulated packet to form a subassembly, thesubassembly disposed within the container at a position covering the atleast one aperture, the container configured to sit on top of a drinkingcontainer to permit liquid to drain into the drinking container from theat least one aperture thereof.

In accordance with yet another aspect of the present invention, a methodof maling a brewing apparatus comprises the steps of: configuring acontainer to store liquid for brewing and to dispense the liquid throughat least one aperture therein; encapsulating a brew substance with alayer of heat sensitive film; covering the encapsulated brew substancewith filter paper to form a subassembly; disposing the subassemblywithin the container at a position covering the at least one aperture;and configuring the container to sit on top of a drinking container topermit liquid to drain into the drinking container from the at least oneaperture thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a break away, isometric illustration of components of abrewing apparatus suitable for embodying one aspect of the presentinvention.

FIG. 1A is a cross-sectional illustration of an encapsulated packet of abrewing substance suitable for use in the embodiment of FIG. 1.

FIG. 2 is a cross-sectional illustration of an assembled brewingapparatus in accordance with the inventive aspect depicted in FIG. 1.

FIG. 3 is an isometric view of a brewing container suitable for use inthe embodiment of FIG. 1.

FIGS. 4A-4C are top, side and isometric views of a sealed packet offilter paper for containing a brewing substance suitable for use in theembodiment of FIG. 1.

FIGS. 5A-5C are top, side and isometric views of a heat sensitive filmlayer suitable for use in the embodiment of FIG. 1.

FIG. 6 is another cross-sectional view of an assembled brewing apparatussuitable for embodying an aspect of the present invention.

FIGS. 6A and 6B are more detailed, cut-away illustrations of portions ofthe assembled brewing apparatus of FIG. 6.

FIG. 7 is an illustration depicting a nesting of containers suitable foruse in the embodiment of FIG. 1.

FIG. 8 is an illustration depicting a nesting of assembled brewingapparatus.

FIG. 9 is a break away, isometric illustration of components of asubassembly containing brewing substance suitable for use in anembodiment of another aspect of the present invention.

FIGS. 10A-10C are top, side and detailed cross-sectional views of theassembled subassembly depicted in FIG. 9.

FIGS. 11A and 11B are top and cross-sectional side views of an assembledbrewing apparatus in accordance with another aspect of the presentinvention.

FIG. 11C is a cut-away, more detailed, cross-sectional view of a portionof the assembly depicted in FIGS. 11A and 11B.

FIGS. 12A and 12B are top and bottom isometric views of a containersuitable for use in the embodiment of FIGS. 11A and 11B.

FIGS. 13A and 13B are top and cross-sectional side views of an assembledbrewing apparatus in accordance with yet another aspect of the presentinvention.

FIGS. 13C-13E are cut-away, cross-sectional views of certain details ofthe assembly depicted in FIGS. 13A and 13B.

FIGS. 14 and 15 are bottom and top cut-away, isometric views of drainapparatus suitable for use in the embodiment of FIGS. 13A and 13B.

FIG. 16 is a break away, isometric view of components of the embodimentof FIGS. 13A and 13B.

FIG. 17 is an isometric illustration of an assembled brewing apparatusseated on a drinking container.

FIG. 18 is an illustration of a nesting of exemplary assembled brewingapparatus.

FIG. 19 is a break away, isometric illustration of components of abrewing apparatus suitable for embodying yet another aspect of thepresent invention.

FIG. 20 is an isometric, cut-away bottom view of the brewing apparatusdepicted in FIG. 19.

FIG. 21 is a break away, isometric illustration of components of abrewing apparatus suitable for embodying yet another aspect of thepresent invention.

DETAILED DESCRIPTION OF THE INVENTION

A suitable embodiment of one aspect of the present invention is depictedin the FIGS. 1 through 6B. FIG. 1 is a break-away, isometric drawing ofcomponents of a brewing apparatus suitable for use in a microwave oven.Referring to FIG. 1, a packet 10 contains a brew substance (not shown)which may be coffee grinds, ground tea leaves, chocolate or otherflavored powder and the like, for example. The brew substance may eveninclude a combination of dry milk and sugar or sugar substitute. Thedifferent views of FIGS. 4A-4C provide more detailed depictions of asuitable brew substance packet 10. As shown in the cross-sectional viewof FIG. 4B, the brew substance is contained within top and bottom filterpaper layers 12 and 14, respectively.

Generally, the filter paper layers 12 and 14 may be comprised of manilahemp, cellulose and thermoplastic fibers, for example. The papermaterial of Crompton #474604 or comparable was found to provide asuitable filter paper layer. Other suitable filter paper characteristicsinclude a weight of 21.0 mg per square inch, air permeability of 50 m³per minute per square meter, a thickness of 89 microns, a wet burststrength of 22 kPa, a dry tensile strength of MD 98 g/mm and CD 34 g/mm,and a seal strength potential of 377 g/50 mm. Preferably, the papershould be food grade compliant to FDA standards 21 CFR 176.170.

The filter paper layers 12 and 14 may be in the form of circles having adiameter of approximately 2.9 inches, for example, as shown in FIGS.4A-4C. The brew substance may be disposed over the bottom paper layer14, preferably forming a pile with the highest point at the center ofthe paper 14. The top paper layer 12 may be disposed over the brewsubstance with its circumference edge aligned with the circumferenceedge of paper 14. The top and bottom paper layers 12 and 14 may besealed together around the circumference thereof to form the packet 10with a relatively flat annular rim 16 of approximately 0.25 inches wideand having a thickness of approximately 8 mils, for example. The sealingprocess may be performed by any of the known commercial methods. FIG. 4Cdepicts the resultant exemplary packet 10 in a 3-dimensional isometricview.

Returning to FIG. 1, the brewing apparatus includes top and bottomlayers 18 and 20, respectively, made of a heat sensitive film. In thepresent embodiment, the top and bottom layers 18 and 20 are of the sameor similar shape. Views of an exemplary top or bottom heat sensitivefilm layer are shown in the FIGS. 5A-5C to provide greater detailthereof. However, it is understood that the film layers 18 and 20 do nothave to be preformed into dome shapes as shown prior to integration withthe coffee packet. The film layers 18 and 20 may be flat, circularblanks that “wrinkle” slightly as they are integrated with the packet10. A suitable heat sensitive material for film layers 18 and 20 isethylene vinyl acetate which is a copolymer film having a thickness ofapproximately 0.00225 inches (0.057 mm), for example. Such a material ismarketed commercially under the trade name of LOMEL by J.D. Rasner & Co.of Beachwood, Ohio, U.S.A. which is food grade compliant to FDAstandards. The top and bottom film layers 18 and 20 may be manufacturedto melt or rupture at different temperatures. For example, the top filmlayer 18 may be manufactured to rupture at approximately 160° F. and thebottom film layer 20 manufactured to rupture at approximately 180° F. Itis understood that other rupture temperatures may be used for the topand bottom film layers 18 and 20 without deviating from the broadprinciples of the present invention.

As shown in FIGS. 5A-5C, each top and bottom film layer 18 and 20 may beshaped as a circle of approximately 2.9 inches in diameter with arelatively flat rim 22 of an approximate width of 0.25 inches around thecircumference thereof, for example. The center section 24 of each filmlayer 18 and 20 may be shaped to conform substantially to the shape ofthe packet 10 so that the top and bottom film layers 18 and 20 may bedisposed over the respective top and bottom surfaces of packet 10 asshown in the cut-away cross-sectional illustration of FIG. 1A. However,as explained in the paragraph directly above, the film layers 18 and 20may take upon other shapes without deviating from the broad principlesof the present invention. Referring to FIG. 1A, the film layers 18 and20 may be heat sealed around the circumference of the rims 22 thereof toform a sealed seam 28. This may be accomplished by any of the well-knownheat sealing techniques like ultrasonic heating, for example. The packet10 containing the brew substance 26 may be thus sealed within the filmlayers 18 and 20 to form an encapsulated sub-assembly 30 of the brewsubstance 26. The process of encapsulating the brew substance in thesub-assembly 30 as described herein above may be performed in a nitrogenenvironment.

Returning to FIG. 1, the brewing apparatus further includes a brewbasket or container 40. In the present embodiment, the container 40 maybe made of a high impact polystyrene material approximately 0.020 inchesthick and configured in a square or rectangular cross-sectional shapewhich is tapered in cross-sectional area from top to bottom. Exemplarydimensions of the container 40 for the present embodiment includeapproximately 4.7 inches per side at the top with a height ofapproximately 2.1 inches. While the present embodiment uses arectangular cross-sectional shape for the container 40, it is understoodthat other cross-sectional shapes may be used, like a cylindrical shape,for example, without deviating from the broad principles of the presentinvention. The container 40 may include a variety of different shapedcontours along the sides and bottom to provide added structural strengthand for design purposes.

At the bottom of the brew container 40 is a cavity 42 which is shownmore clearly in the cross-section view of FIG. 2 and isometric view ofFIG. 3. The cavity 42 may be configured in a frusto-conical shape in thepresent embodiment to accommodate the sub-assembly 30 as shown in FIG.2, but other shapes will suffice as well. At the bottom of the cavity 42is an aperture 44 which may be circular in configuration and encompass asubstantial portion of the bottom portion of the cavity 42 as shown inFIG. 3. FIGS. 6, 6A and 6B depict the container 40 of the presentembodiment in greater detail. FIG. 6 is another cross-sectional view ofthe container 40 showing protrusions or feet 46 extending from thebottom surface and on which the container 40 may rest in an uprightorientation. The feet 46 may also be seen in FIGS. 2 and 3. Thecross-sectional illustration of FIG. 6A reveals one of the feet 46 ingreater detail.

In the present embodiment, the feet 46 are disposed along the outerbottom edge and aligned substantially with the four corners of therectangular cross-section of the container 40. However, it is understoodthat the feet 46 may be disposed around the bottom edge in any patternof separation. While four feet 46 are depicted in the presentembodiment, it is understood that three feet 46 may be used just as wellso long as they are suitably separated from each other around the outerbottom edge of container 40.

To complete the assembly of the brewing apparatus, the sealedsub-assembly 30 is disposed in the cavity 42 as shown in thecross-sectional views of FIGS. 2 and 6. As shown in FIG. 6B which is amore detailed cut-away, cross-sectional view of the sub-assembly 30resting in the cavity 42, the rim 22 of the sub-assembly 30 is seatedcircumferentially around an edge 50 of the bottom surface of thecontainer 40. Note that the weight of the sub-assembly 30 creates a sealagainst the side walls of the cavity 42 during a brewing process as willbecome better understood from the description found herein below.Alternatively, the packet 10, film layers 18 and 20 and container 40 maybe integrated in a single step.

FIG. 7 depicts a cross-sectional view of a nesting of a plurality of thebrewing baskets 40 for storage prior to the assembly process describedhere above. Note that the baskets 40 are configured in shape to fitclosely within each other so that they take up little space duringstorage. FIG. 8 depicts a cross-sectional view of a nesting of aplurality of the assembled brewing apparatus which may be stackedclosely within each other. Accordingly, a stack of a plurality ofassembled brewing apparatus may be packaged together for retail salewithout taking much space on the shelves of the retailer or consumer.

Upon purchase of a retail package, the consumer may remove a brewingunit from the package and fill the container 40 to a suitable level witha desired liquid, like water, for example. If the brewer unit is to beused for single cup brewing of a liquid, the consumer may fill thecontainer 40 with 8 or 9 ounces of the liquid, for example. A fill linemay be provided for this purpose on one or more inside side surfaces ofthe container 40. Note that the weight of the liquid in the basket 40will press the sub-assembly 30 firmly against the walls of the cavity 42as shown in FIG. 6B. Then, the brewer unit may be placed on top of adrinking container which may be a mug, for example, so that the bottomsurface of the cavity 42 rests on the circumference of the top edge ofthe mug as shown in FIG. 17. Note that the aperture 44 will fall withinthe top opening of the drinking container and the feet 46 will centerthe aperture 44 over the opening of the mug and keep the container 40from sliding across the top edge of the mug.

Thereafter, the brewer unit and mug may be disposed within a microwaveoven for heating which may take a few minutes depending upon the powerof the oven. In the present embodiment, when the temperature of theliquid reaches the rupture temperature of the top film layer 18, whichmay be around 160° F., the film layer 18 will begin to weaken andrupture creating a pealing of the layer 18 starting at the rupturepoint(s) and moving toward the outside periphery exposing the filterpaper layer 12. At this point the hot liquid will penetrate the paperlayer 12 and mix with the brew substance. Note that the bottom filmlayer 20 has not yet ruptured, thus permitting the hot liquid to sitwithin and wet the particles of the brew substance 26 throughout theentire volume thereof providing for a more uniform infusion of theflavor of the brew substance into the brewing liquid.

The brewing liquid will continue to be heated by the microwave oven.Then, as the liquid reaches the rupture temperature of the bottom layer20, which may be around 180° F., for example, the bottom layer 20 willrupture in a similar manner as the top layer 18, thereby dispensing thebrewed liquid by gravity through filter paper 14 and aperture 44 intothe drinking container. The brewing process may proceed for severalminutes beyond the microwave cycle. Thereafter, the brewed liquid iswithin the drinking container. Note that the top and bottom filter paperlayers 12 and 14 will keep the particles of the brew substance 26 withinthe containment volume of the packet 10 to ensure the full infusion offlavor during the brewing process. For a brewing of coffee, for example,the brewing cycle may take on the order of 3-5 minutes. For otherbrewing, the brewing time may vary depending on the liquid and brewsubstance used. Brewing time will also vary depending on the power ofthe microwave oven being used.

Some advantages of the foregoing described embodiment are as follows.Encapsulating the brew substance charge packet within the heat sensitivefilm layers provides preservation of the brew substance charge for eachunit for some time after the retail package is ruptured. No userinteraction is required to rupture or remove the film seal of theencapsulated packet as this occurs automatically in the brewing process.In addition, the phased exposure of the brew substance charge allowscapillary action to first allow a small amount of liquid to gentlypermeate the brew substance before the higher flow rate brew processcommences, thereby allowing a greater portion of the liquid in thereservoir to flow through a wetted brew substance charge.

Further, the present embodiment contains the brew substance in a stableshape within the filter packet, thereby keeping hydraulic drag uniformand predictable as is preferred for consistent extraction from onebrewer to the next. Also, the brew substance charge is held in positionwhere the fluid head pressure is great. Note that the brew substance isentirely contained within the filter paper packet which keeps the brewsubstance from entering the liquid reservoir.

FIG. 9 is a break away, isometric view of components of a sub-assemblyunit 60, for containing the brew substance, suitable for use in analternate embodiment of the brewing apparatus. Referring to FIG. 9, topand bottom heat sensitive film layers 62 and 64, respectively,encapsulate the brew substance 66 which in this embodiment may be coffeegrounds, for example. The film layers 62 and 64 may be of the same orsimilar type and configuration as described herein above for the layers18 and 20 and may be heat sealed together around the periphery of therim portions thereof to fully encapsulate the brew substance. Inaddition, top and bottom filter paper layers 68 and 70, respectively,are disposed over and affixed to the surfaces of respective top andbottom film layers 62 and 64 to form the sub-assembly 60 which is shownby top and side views of FIGS. 10A and 10B, respectively. The filterpaper layers 68 and 70 may be of the same or similar type andconfiguration as described herein above for the paper layers 12 and 14.FIG. 10C is a more detailed cross-sectional view of the layers 62, 64,68 and 70 of the sub-assembly 60.

In the above manner, an encapsulated sub-assembly of the brew substancemay be formed as a separate sub-assembly, then subsequently affixed to aliquid reservoir structure by ultrasonic, vibration, laser or heatwelding, for example, as will be described in more detail in connectionwith FIGS. 11A-C. The described topology permits the use of relativelycommon sub-assembly forming machinery. By comparison, encapsulation ofthe coffee grounds in prior concepts would necessarily require a custommachine capable of handling the molded reservoir in addition to thepaper and plastic layers in a nitrogen environment. With the instantsub-assembly, only its manufacture will take place in a nitrogenenvironment and not the assembly of the entire brewer unit. It ispreferable to provide a 100% nitrogen environment near the assemblyprocess as well as that trapped in the encapsulated package to displacepotentially harmful oxygen.

FIGS. 11A and 11B depict top and side views of a liquid reservoir basket72 containing the brew substance sub-assembly 60 disposed over a bottomliquid diffuser section 74 that is shown in greater detail in the topand bottom isometric views of FIGS. 12A and 12B. In this alternateembodiment, the reservoir 72 is square or rectangular in cross-sectionand the bottom diffuser section 74 is cylindrical in shape and containsspokes 76 attached between the outer periphery of the section to a point78 at a center of the section. The spokes 76 are disposed uniformlyabout the opening periphery to create wedge shaped openings therebetweenthrough which liquid may be dispensed from the reservoir 72.

FIG. 11 C is an enlarged cross-sectional view illustrating how the rim73 of the sub-assembly 60 rests circumferentially on a ledge 76 of thereservoir 72 disposed around the bottom surface thereof. As noted above,the rim 73 of the sub-assembly 60 may be affixed to the ledge 76 of theliquid reservoir structure 72 by ultrasonic, vibration, laser or heatwelding, for example. Also, as shown in FIGS. 12A and 12B, feet 80 maybe formed or attached about the bottom periphery of the reservoir 72,preferably aligned with the four corners of the rectangularcross-section thereof. The cylindrical diffuser section 74 may extend adistance below the feet 80 so that when the reservoir 72 rests on thetop edges of a drinking container during the brewing process asdescribed herein above, the cylindrical diffuser section 74 will fallwithin the opening of the drinking container. The passage way fromreservoir 72 or open area of diffuser section 74 over which the brewsubstance sub-assembly 60 is disposed is large and less restrictive inthe instant embodiment. The large opening will result in more uniformcontact between water and coffee grounds, ultimately providing improvedextraction and shorter brewing times.

A few points regarding the proposed sub-assembly construction are asfollows: the filter paper layer on top prevents buoyant grounds fromrising into water reservoir (i.e. keeps grounds in a brew chamber foroptimal extraction); the filter paper layers on top and bottomfacilitate the thermal fusing due to the fact that the paper preventsthe melted plastic films from adhering to the heating die (It isbelieved that the same benefit might be observed in the ultrasonicwelding process); as before, the top and bottom dual heat sensitive filmconstruction provides a freshness seal, particularly one that requiresno user intervention to breach; the difference in melting temperaturesbetween top film layer upstream of the bottom film layer provides twofunctions: (a) assurance that the lower film will eventually rupture(not guaranteed if both films are the same melt point because waterloses temperature as it passes through the grounds), and (b) lower filmretains hot water momentarily in a brew chamber to assure goodsaturation of grounds.

As noted above, a suitable material for the reservoir 72 is styrofoam(a.k.a., EPS, expandable polystyrene) which may be EPS molded into thedesired configuration or shape due to its superior thermal insulatingproperties. Use of this material will shorten microwave heating time ofthe brewing liquid when compared with more dense plastic materials. Alsonoted above, multiple brewer assemblies may be nested for efficientpackaging. The use of a sealed multi-pack retail container (not shown)is intended to provided a freshness seal (in addition to the individualsealing of the coffee within each “brewer” provided by the two EVA filmlayers in each sub-assembly. The sealing of each individual sub-assemblypermits the freshness seal of the multi-pack container to be opened andstill preserve the freshness of the brew substance within the individualsub-assemblies.

An exemplary embodiment of brewing apparatus in accordance with anotheraspect of the present invention is depicted in FIGS. 13A-16. Referringto FIGS. 13A and 13B which depict top and cross-sectional views of thisbrewing apparatus, a liquid reservoir 90 is shown having a squarecross-section which tapers in cross-sectional area from top to bottom.Attached to the bottom of the reservoir 90 is a brewing chamber 92 whichis cylindrical in shape. The reservoir bottom is sloped toward a drainarea 94 which forms a passageway between the reservoir 90 and thebrewing chamber 92. The reservoir 90 is designed to hold the brewingliquid, which may be water, for example. Liquid is typically added toand then heated in the reservoir 90 within a microwave oven. Pre-heatedliquid may be added to speed the microwave heating process. Very hotliquid may be used to avoid using the microwave oven completely.

As noted above, the reservoir 90 preferably has a square or rectangularcross-sectional shape but may be any shape. A square or rectangularshape maximizes the holding capacity of the reservoir for space used ina microwave oven. The shape of the inventive brewing apparatus ispreferable because it allows the brewer to fit the apparatus in thesmall compartments within any known microwave ovens. For example,comparing round and square reservoirs having an equal diameter and sidelength respectively and equal heights, the square reservoir has agreater volume capacity. It follows that a square reservoir with thesame volume capacity and side length as a round reservoir diameter mayhave a shorter height. This is beneficial if the microwave oven in usehas a compact design. Although, the primary benefit of nesting ispotentially permitting the placement of a greater number of units on thelimited area of a retail shelf. Many different shapes of the reservoirmay be nested with equal vertical efficiency. Nested circular shapes arepreferred because they can be oriented in an infinite continuum, whereasa rectangular shape has only four nesting positions 90° apart.

The reservoir 90 may be made from a transparent or translucent material.This allows for visible observation of liquid level within thereservoir. A preferred material is polypropylene. The polypropylene mayhave a melting temperature of about 210° F. The reservoir 90 may includea reinforcing seam 91 as shown in FIG. 13B. The seam 91 may servemultiple purposes. First, the seam 91 may add to the rigidity of thereservoir 90, preventing it from being crushed easily. Second, the seam91 may be positioned to act as a fill line that permits a user to knowwhen a desired volume of liquid has been poured into the reservoir 90.

The reservoir 90 may include a series of feet 93 upon its bottomsurface. The feet 93 may have varying configurations. The feet 93 of thepresent embodiment may be similar to the feet 80 shown in FIG. 12Bwherein each foot is formed by a pair of parallel protrusions. Theprotrusions bend towards each other at the periphery of the reservoirand are joined (i.e. rounded). At the opposite end, the protrusions abuta wall of the brewing chamber 92 (see FIG. 14). In an alternateembodiment each foot may be a single protrusion. The feet 93 function toprovide strength and rigidity to the base of the reservoir and act as asupport for the brewer upon a cup or mug. The extended length of eachfoot allows a single sized brewer to be stably placed upon drinkingcontainers of varying diameters. Thus, the brewer is universal toseveral types and sizes of mugs and cups. In other embodiments, the feet93 may not be necessary.

The drain assembly 94 functions as a liquid passageway between thereservoir 90 and the brewing chamber 92. Refer additionally to FIG. 14which is a cut-away, isometric bottom view of the inside of the brewingchamber 92 and to FIG. 15 which is a cut-away, isometric top view of thebase of the reservoir 90, both views showing the drain assembly 94 ingreater detail. The drain assembly 94 may include an aperture 96 withinthe base of the reservoir 90. The aperture 96 may be covered with a heatsensitive film seal 98 described in more detail below. The drainassembly may also include a diffuser extension 100 which extendsdownward from the base of the reservoir 90 through the aperture 96. Thediffuser extension 100 may be integrally formed with the reservoir 90.

The diffuser extension 100 may include a number of spokes 102 extendingfrom a center axial member 104, which is oriented downward transverselyto the aperture 96, to the wall of the aperture 96 (see FIG. 15). Thestructure of the axial member 104 and spokes 102 extends below theaperture 96 (see FIG. 14) to form wedge shaped open areas to the brewingchamber 92. The axial member 104 and spokes 102 defining these wedgeshaped open areas act as a structural support frame. The supportproperties of the diffuser extension 100 also prevent a filter paperlayer, which is positioned below the drain assembly 94 from beingdeformed upwards during packaging or handling of the brewer as willbecome more evident from the description herein below. The open areas orapertures within the diffuser extension 100 in combination with thesupport frame allow liquid flowing through the drain assembly 94 to bespread radially through the brew chamber 92 as opposed to beingconcentrated in a position directly below the reservoir aperture 96. Thepresence of a diffuser structure is important to both the taste of thebrewed liquid and the uniform time of brewing for all brew substanceparticles in the brewing chamber 92.

In the present embodiment, the brewing chamber 92 is defined by acircular wall extending down from the bottom of the reservoir 90. Thebrewing chamber 92 may have any shape however. The brewing chamber holdsthe brew substance 106 which may be coffee grinds, for example. Thegrind size of the coffee grounds may be varied to meet the desiredbrewing characteristics. The grind size may also vary depending upon thetype of coffee caffeinated, or decaffeinated being used. Filter paper108 supports the brew substance 106 within the brewing chamber 92. Thebrewing chamber 92 is open on its base but for the presence of the paperfilter 108 and another heat sensitive film seal 110 as described below.In one embodiment, the height and diameter of the open base of the brewchamber are about 0.5 inches and 2.25 inches, respectively. Incomparison, the aperture 96 in the bottom of the reservoir may have adiameter of about 0.5 inches in the same embodiment (a 4.5 to 1 ratio).This ratio may be adjusted to achieve the desired brew characteristics.

As noted above, the brewing chamber 92 holds a charge of brew substance106, which may be coffee, through which hot brewing liquid, like water,will flow. The particle or grind size of the brew substance charge maybe varied according to the brew substance being used. The grind size mayalso be modified to vary the residence time of the liquid within thebrew chamber 92 as well as to vary the flow characteristics of theliquid across the charge of grounds. In addition to the use of differenttypes or flavors of brew substance, substance complements or substitutesmay be used. Sweetener or powdered dairy products may be mixed with thegrounds. Alternatively, the sweetener or powdered dairy products may beplace as separate stratified layers within the brew chamber 92. Thestratified layers may be placed in any order. The stratified layers bybe separated by filter paper layer 108, heat sensitive film seal layer110 or by no material at all. The charge 106 of the particles of brewsubstance and perhaps complements may be pressed into a puck shaped formusing conventional press machinery.

The paper filter layer 108 is disposed below the brew substance charge106 to prevent grounds from entering the cup or mug of the brewer. Thefilter 108 may have varied characteristics such as fiber type, size,denier, length and configuration. These characteristics may be varied toachieve desired brew scenarios. For example, the residence time withinthe brewing chamber may be controlled. Additionally, the degree thewater spreads radially within the brewing chamber may be controlled.

The paper filter layer 108 may be adhered to the walls 112 of thebrewing chamber 92 using a ultrasonic joining process as shown in themore detailed cross-sectional sketch of FIG. 13D. The brewing chamberwalls 112 are formed to define a point 114 at their lowermost extremity.The paper filter layer is brought into contact with the brewing chamberat these points 114 and manipulated to form a connection as shown inFIG. 13D. This joining process may be repeated at the lowermost wall ofthe diffuser extension as shown in the more detailed cross-sectionalsketch of FIG. 13E. As shown in FIG. 13E, the diffuser extension 100defines a circular joining surface 116 at its base. Other methods ofjoining the filter 108 to the brewer apparatus may also be used such asadhesives or heat deformation of one or both of the joining materials.

In an alternate embodiment, the brew substance charge 106 may becontained in a sub-assembly pouch comprising a filter material asdescribed herein above. Alternatively, the pouch may also be comprisedof a film seal material also described above.

In the present embodiment, a heat sensitive film seal may be disposedover, thus blocking, the aperture 96 at the bottom of the reservoir 90(see layer 98 in FIG. 13C) or, in a position beneath the filter paperlayer 108 (see layer 110 in FIG. 13D), or in both positions. The heatsensitive film seal may provide one or more functions. First, the filmmay act as a heat sensitive valve device. At room temperature, the sealacts as a physical barrier between two areas. As liquid is heated in anarea on one side of the film, a failure scenario begins. A set amount oftime elapses before the heat of the hot liquid causes the film torupture or fail. This amount of time may be a function of severalfactors:

-   -   1) The time required for the microwave oven to bring the liquid        temperature to a temperature which begins to break down or        rupture the film. In one embodiment, this “critical temperature”        may be from about 195° F. to 205° F.; and    -   2) The films durability at the critical temperature which can be        a function of the material of selection of the film, the        thickness of the film, and the overall size of the film. A        preferred film material is Ethylene Vinyl Acetate or Lomel. This        material may have a melting or rupture point of about 160° F. A        preferred film thickness is from about 0.0015 inches to 0.0030        inches. The film may be provided in colors or in a transparent        form.

Preferably, the heat sensitive film layer 98 fails in a manner whereinthe opening or aperture 96 formerly covered by the seal 98 is almostcompletely opened. In combination with this large degree of shrinkage inthe film 98, the film still will not break into pieces, thus no bits ofseal material will be received in the consumer's cup or mug.

One benefit of using the heat sensitive film layer 110 below the filterpaper layer 108 is to increase the residence time of the hot liquidwithin the coffee grounds. When the two film seals 98 and 110 are used,they may be designed to have identical or varied failure properties. Inone method of brewing, the upper seal film 98 is designed to fail at180°-190° F. and the lower seal at 160°-170° F., but these temperatureproperties may be reversed. The failure temperature can be controlled bythe film material used and the thickness of the material.

The dual film layers 98 and 110 may provide a second function of sealingthe coffee grounds from the atmosphere. Humidity, smells or contaminantsmay be present in the surrounding air and should be isolated from thecoffee grounds. The dual film layers may be gas permeable but may alsobe designed to provide the necessary air tight seal. The dual filmlayers increase the shelf-life of the brewer for storage purposes in auser's home. It locks in freshness.

In the embodiment utilizing the film seal 98 to cover the reservoiraperture 96 and the film seal 110 disposed below the filter paper layer108, an alternative film material such as foil may be used in one of thepositions if heat sensitive properties are not necessary. The film seals98 and 110 may be held in place with an adhesive using an ultrasonicjoining process similar to that described above with respect to thefilter 108, by a fastener such as an o-ring, or by melting the film tothe brewer. FIG. 13C shows the film layer 98 joined to the brewer bottomat annular protrusions or raised ribs 120 encircling the drain area 94in close proximity to the aperture 96. The one or more ribs 120 raisedfrom the reservoir floor provide binding surfaces for the film seal 98.Beneath the filter paper layer 108, the film seal 110 bonds to a point122 on the wall 112 of the brewing chamber (see FIG. 13D) which extendsbelow and to the outside of the point where the filter is bound.

Referring to the break-away, isometric view of the brewing apparatus ofthe present embodiment shown in FIG. 16, a preferred method ofmanufacturing the brewing apparatus includes sealing the aperture 96 inthe bottom of the reservoir 90 with the heat sensitive film while thereservoir 90 is in an upright position; and then, rotating the reservoir90 180 degrees so that the bottom is upright. In this rotated position,the charge 106 of brew substance is disposed in place within the brewchamber 92; the paper filter layer 108 is then disposed in place andattached to the points 114 and 116 as described herein above; and then,the second film seal layer 110 is disposed over the opposite side of thefilter from the brew substance charge 106 and attached to point 122 ofthe wall 112 of the brewing chamber 92.

FIG. 17 is an illustration of a brewing apparatus 130 having acylindrically shaped reservoir engaged on a cup 132 for brewing in amicrowave oven. The liquid fill capacity of the reservoir 130 for singlecup brewing is between 8 to 9 ounces (8 oz. fill is intended to yield 7to 7½ ounces of drinkable coffee, whereas a 9 ounce fill yieldsapproximately 8 oz of drinkable coffee). As noted above, the squarecross-sectional shaped reservoir is believed to allow better utilizationof available product shelf space, allowing both the retailer and user toincrease nesting efficiency.

FIG. 18 illustrates the proposed retail packaging of the brewers in anexemplary nested or stacked configuration. The nested brewers may thenbe stored in a metal or paper tin for sale. The outer tin cover mayprovide an additional seal to protect from spoilage.

FIGS. 19 and 20 depict exemplary brewing apparatus suitable forembodying yet another aspect of the present invention. FIG. 19 is abreak-away, isometric view of the components of the present embodiment.Many of the components of the embodiment of FIG. 19 are the same instructure and function as described above for the embodiment of FIGS.13A-16. These same components will not be further described and thereference numbering will be maintained the same for the presentembodiment. Referring to FIG. 19, a spring loaded valve assemblycomprising a spring 134 and valve 136 are disposed in the brewingchamber 92 at the aperture 96. One end of the spring 134 is attached tothe valve 136 and the other end is attached to the circumference of theaperture 96. The valve 136 includes a flat, circular center surface 137and three resilient legs 138 attached around the periphery of thesurface area 137 at points that are approximately 120° apart. The endsof the legs 138 comprise elongated surface areas 140 transverse the legs138. The surface areas 140 of legs 138 are attached to respective areasof the bottom of the reservoir 90 within the brewing chamber 92 as shownin the cut-away, isometric view of FIG. 20.

Prior to brewing, the spring 134 is maintained in a compressed state topermit the flat surface 137 of the valve 136 to cover and seal theaperture 96 of the reservoir 90. In the present embodiment, the spring134 is maintained in the compressed state by a temperature sensitive waxmaterial which may be also used to attached the spring 134 to the valvesurface 137. The wax material used for the present embodiment includesan amide wax, such as ethylene bis-stearamide, as well as a long chainketone, like stearone, for example. But, it is understood that otheringredients may be used for the wax just as well.

During the brewing process, as the temperature of the reservoir liquidincreases, the wax material is eventually melted, allowing the spring134 to extend to its uncompressed state. A suitable melting temperatureof the wax material may be approximately 160 to 190 degrees F. Thisextension of the spring 134 forces the surface area 137 away from theaperture 96, thus creating an opening or passageway for the heatedliquid to enter the brewing chamber 92 from the reservoir 90 and mixwith the brew substance 160. The legs 138 act as guide bosses to preventthe valve surface 137 from floating back up into a sealed position afterthe wax releases. Eventually, the bottom film seal layer 110 willrupture permitting the hot brewed liquid to be dispensed through thepaper filter layer 108 and into the mug 132. In this embodiment, theupper film seal layer 98 may be dispensed with because the valveassembly itself is temperature sensitive and functions in a similarmanner.

A break-away, isometric view of components of a brewing apparatussuitable for embodying yet another aspect of the present invention isshown in FIG. 21. Referring to FIG. 21, the present embodiment comprisesa cylindrically shaped liquid reservoir 150, which may be made ofpolypropylene, for example, having a small liquid dispensing aperture(not shown) in the bottom thereof. A top heat sensitive film seal 152,which may be a foil-laminate, for example, may be used to cover and sealthe dispensing aperture in the reservoir 150. A valve assembly 154similar to the valve assembly described here above may be attached tothe outside bottom of the reservoir 150 to cover and seal the dispensingaperture. The valve 154 may be made of a polycarbonate material, forexample, and operate in a similar manner to the valve 136.

In addition, a brew funnel 156 which may be also made of polypropylene,for example, is attachable to the base of the reservoir 150. The brewfunnel 156 includes a brew chamber therein for supporting a filter paperlayer 158 and a charge of brew substance 160. The bottom of the brewfunnel 156 includes at least one aperture for dispensing brewed liquidtherefrom. The filter paper layer 158 may be disposed on and, possiblybonded to, a ring ledge 162 formed along the inner periphery of the brewfunnel 156 and the charge 160 may be disposed over the filter paper 158.A bottom heat sensitive film seal layer 164 may be attached to thebottom of the funnel 156 to cover and seal the at least one aperturethereof. The embodiment of FIG. 21 may operate in a similar manner tothat described for the embodiment of FIGS. 19 and 20.

While the present invention has been described herein above inconnection with a plurality of embodiments, it is understood that suchpresentation was provided strictly by way of example without any intentof limiting the invention in any way. Accordingly, the present inventionshould not be limited by the embodiment descriptions presented hereinabove, but rather construed in breadth and broad scope in accordancewith the recitation of the appended claims hereto.

1. Apparatus for brewing a brew substance with a liquid, said apparatuscomprising: a container for storing the liquid, said container includingat least one aperture for dispensing liquid therefrom; a sealed packetof filter paper containing the brew substance; and a layer of heatsensitive film encapsulating said sealed packet, said encapsulatedpacket disposed within said container at a position covering said atleast one aperture, said container configured to sit on top of adrinking container to permit liquid to drain into said drinkingcontainer from said at least one aperture thereof.
 2. The apparatus ofclaim 1 wherein the encapsulated packet is secured within the container.3. The apparatus of claim 1 wherein the container includes a cavityconfigured to accept the encapsulated packet; and wherein theencapsulated packet is disposed at said cavity.
 4. The apparatus ofclaim 3 wherein the cavity is at a bottom of the container; and whereinthe cavity includes a single aperture that covers a substantial area ofthe cavity.
 5. The apparatus of claim 3 wherein the encapsulated packetincludes a substantially flat rim about the periphery thereof; whereinthe container includes a ledge configured about the periphery of thecavity; and wherein the rim of the encapsulated packet is seated on saidledge.
 6. The apparatus of claim 5 wherein the rim of the encapsulatedpacket is secured to the ledge.
 7. The apparatus of claim 1 wherein thesealed packet includes a top and bottom surface; and wherein theencapsulated packet includes: a first layer of heat sensitive filmcovering said top surface of the sealed packet; and a second layer ofheat sensitive film covering said bottom surface of the sealed packet,said first and second layers being attached together along the outerperiphery thereof to encapsulate said sealed packet within said firstand second layers.
 8. The apparatus of claim 7 wherein the first andsecond layers of heat sensitive film have different rupturetemperatures.
 9. The apparatus of claim 7 wherein the first layer ofheat sensitive film has a rupture temperature lower than the rupturetemperature of said second layer of heat sensitive film.
 10. Theapparatus of claim 7 wherein the first layer of heat sensitive film hasa rupture temperature of approximately one hundred and sixty degreesFahrenheit and the second layer of heat sensitive film has a rupturetemperature of approximately one hundred and eighty degrees Fahrenheit.11. The apparatus of claim 1 wherein the container is configured with aplurality of feet to prevent the container from slipping off thedrinking container when seated on top thereof.
 12. The apparatus ofclaim 1 wherein the container is configured to permit a nesting of aplurality of containers by disposing one within the other.
 13. Theapparatus of claim 1 wherein the container is configured to have arectangular cross-section tapered from top to bottom.
 14. The apparatusof claim 1 wherein the brew substance comprises coffee grinds and theliquid comprises water.
 15. The apparatus of claim 1 wherein thecontainer is configured to store a single serving quantity of liquid;and wherein the sealed packet contains a single serving charge of brewsubstance.
 16. The apparatus of claim 1 wherein the container and layerof heat sensitive film are made of material suitable for microwaveheating.
 17. Method of making a brewing apparatus, said methodcomprising the steps of: configuring a container to store liquid forbrewing and to dispense said liquid through at least one aperturetherein; encapsulating a sealed packet of filter paper containing a brewsubstance with a layer of heat sensitive film; disposing saidencapsulated packet within the container at a position covering said atleast one aperture; and configuring said container to sit on top of adrinking container to permit liquid to drain into said drinkingcontainer from said at least one aperture thereof.
 18. The method ofclaim 17 including the step of securing the encapsulated packet withinthe container.
 19. The method of claim 17 including the steps of:configuring a bottom of the container with a cavity formed to accept theencapsulated packet; and disposing the encapsulated packet at thecavity.
 20. The method of claim 17 wherein the step of encapsulatingincludes: covering a top surface of the sealed packet with a first layerof heat sensitive film; covering a bottom surface of the sealed packetwith a second layer of heat sensitive film; and attaching together saidfirst and second layers along the outer periphery thereof to encapsulatesaid sealed packet within said first and second layers.
 21. The methodof claim 20 wherein the top and bottom surfaces of the sealed packet arecovered with layers of heat sensitive film having different rupturetemperatures.
 22. The method of claim 20 wherein the top surface of thesealed packet is covered with a first layer of heat sensitive filmhaving a first rupture temperature; and wherein the bottom surface ofthe sealed packet is covered with a second layer of heat sensitive filmhaving a second rupture temperature higher than said first rupturetemperature.
 23. The method of claim 20 wherein the top surface of thesealed packet is covered with a first layer of heat sensitive filmhaving a rupture temperature of approximately one hundred and sixtydegrees Fahrenheit; and wherein the bottom surface of the sealed packetis covered with a second layer of heat sensitive film having a rupturetemperature of approximately one hundred and eighty degrees Fahrenheit.24. The method of claim 17 including configuring the container with aplurality of feet to prevent the container from slipping off thedrinking container when seated on top thereof.
 25. The method of claim17 including configuring the container to permit a nesting of aplurality of containers by disposing one within the other.
 26. Themethod of claim 17 including configuring the container to have arectangular cross-section tapered from top to bottom.
 27. The method ofclaim 17 including making the container and layer of heat sensitive filmwith material suitable for microwave heating.
 28. Apparatus for brewinga brew substance with a liquid, said apparatus comprising: a containerfor storing the liquid, said container including at least one aperturefor dispensing liquid therefrom; an encapsulated packet of heatsensitive film containing the brew substance; and a layer of filterpaper covering said encapsulated packet to form a subassembly, saidsubassembly disposed within said container at a position covering saidat least one aperture, said container configured to sit on top of adrinking container to permit liquid to drain into said drinkingcontainer from said at least one aperture thereof.
 29. The apparatus ofclaim 28 wherein the subassembly is secured within the container. 30.The apparatus of claim 28 wherein the encapsulated packet includes: afirst layer of heat sensitive film forming a top surface; and a secondlayer of heat sensitive film forming a bottom surface, said first andsecond layers being attached together along the outer periphery thereofto encapsulate the brew substance.
 31. The apparatus of claim 30 whereinthe first and second layers of heat sensitive film have differentrupture temperatures.
 32. The apparatus of claim 28 wherein the brewsubstance comprises coffee grinds and the liquid comprises water. 33.The apparatus of claim 28 wherein the container is configured to store asingle serving quantity of liquid; and wherein the encapsulated packetcontains a single serving charge of brew substance.
 34. The apparatus ofclaim 28 wherein the container and layer of heat sensitive film are madeof material suitable for microwave heating.
 35. Method of making abrewing apparatus, said method comprising the steps of: configuring acontainer to store liquid for brewing and to dispense said liquidthrough at least one aperture therein; encapsulating a brew substancewith a layer of heat sensitive film; covering the encapsulated brewsubstance with filter paper to form a subassembly; disposing saidsubassembly within the container at a position covering said at leastone aperture; and configuring said container to sit on top of a drinkingcontainer to permit liquid to drain into said drinking container fromsaid at least one aperture thereof.
 36. The method of claim 35 includingthe step of securing the subassembly within the container.
 37. Themethod of claim 35 including the steps of: configuring a bottom of thecontainer with a cavity formed to accept the subassembly; and disposingthe subassembly at the cavity.
 38. The method of claim 35 wherein thestep of encapsulating includes: disposing the brew substance on a firstlayer of heat sensitive film; applying a second layer of heat sensitivefilm over the brew substance to form a top surface of the encapsulatedpacket; and attaching together said first and second layers along theouter periphery thereof to encapsulate said brew substance within saidfirst and second layers.
 39. The method of claim 38 wherein the firstand second layers of heat sensitive film encapsulating the brewsubstance have different rupture temperatures.
 40. The method of claim35 wherein the step of covering includes: disposing first and secondsheets of filter paper about the encapsulated packet; and sealingtogether the first and second sheets at the outer periphery thereof toform the subassembly.